Structural frame

ABSTRACT

A structural frame is provided. The structural frame includes a bottom surface, first and second cylinder block sidewall engaging surfaces, the first and second cylinder block sidewall engaging surfaces positioned above the bottom surface at a height that is above a centerline of a crankshaft support included in a cylinder block when the structural frame is coupled to the cylinder block.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/270,100, “STRUCTURAL FRAME,” filed Oct. 10, 2011, which claimspriority to U.S. Provisional Patent Application No. 61/428,119,“CYLINDER BLOCK ASSEMBLY,” filed Dec. 29, 2010, the entire contents ofeach of which are hereby incorporated by reference for all purposes.

BACKGROUND Summary

Internal combustion engine are continually being refined to increase theoutput of the engine as well as reduce the engine's weight and/or size.Boosting devices, such as turbochargers and superchargers, have beenadded to engines so that the engines may have output similar to largerdisplacement engines without the fuel economy and emissions of largerdisplacement engines. Further, vehicle fuel economy may be improved invehicles having smaller engines at least in part because smaller enginesmay weigh less than larger displacement engines. Alternatively, outputpower of an engine may be substantially increased without adding asignificant amount of weight to the engine. Additional techniques forincreasing engine power such as direct injection may also be usedwithout significantly increasing the engine's weight.

However, decreasing engine size and/or increasing engine power outputcan increase stress on the engine components. Such concerns may beparticularly present for boosted engines which typically have a highpower to weight ratio as compared to naturally aspirated engines.Therefore, some boosted engines are comprised of increased amounts ofmaterial, such as aluminum, to reinforce the cylinder block. But,increasing the amount of material used to form the cylinder block canincrease engine weight, thereby undermining the basic objective ofincreasing the engine's power to weight ratio.

The inventors herein have recognized the challenges of boosting a weightreduced engine and have provided a structural frame. The structuralframe includes a bottom surface, first and second cylinder blocksidewall engaging surfaces, the first and second cylinder block sidewallengaging surfaces positioned above the bottom surface at a height thatis above a centerline of a crankshaft support included in a cylinderblock when the structural frame is coupled to the cylinder block.

By raising the height of structural frame sidewalls it is possible toincrease the strength of the cylinder block assembly while at the sametime reducing weight of the cylinder block assembly. In particular, thestructural frame may provide support to the cylinder block while beingconstructed of a lighter weight material. Further, the structural framemay include a mounting surface for interfacing to at least a portion ofa transmission bell housing. Thus, the structural frame may support andstrengthen both the cylinder block and a transmission.

Further, in some examples, the structural frame may include variousintegrated components such as an oil pump, oil filter, cooler, oilby-pass system, and/or oil passages. When the aforementioned componentsare integrated into the structural frame, the compactness of the enginemay be increased and engine assembly may be simplified.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. Furthermore,the claimed subject matter is not limited to implementations that solveany or all disadvantages noted in any part of this disclosure.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a schematic depiction of an internal combustion engine.

FIG. 2 shows another schematic depiction of the internal combustionengine shown in FIG. 1 including a cylinder block assembly.

FIG. 3 shows an exploded perspective view of an example cylinder blockassembly.

FIG. 4 shows an assembled view of the cylinder block assembly shown inFIG. 3.

FIG. 5 shows a bottom view of a structural frame included in thecylinder block assembly shown in FIG. 3.

FIG. 6 shows a rear end view of the cylinder block shown in FIG. 3.

FIG. 7 shows a rear end view of the structural frame shown in FIG. 3.

FIG. 8 shows a rear end view of the cylinder block assembly shown inFIG. 4.

FIG. 9 shows a left side view of the cylinder block assembly shown inFIG. 4.

FIG. 10 shows a right side view of the cylinder block assembly shown inFIG. 4.

FIG. 11 shows front end view of the cylinder block shown in FIG. 3.

FIG. 12 shows front end view of the structural frame shown in FIG. 3.

FIGS. 13 and 14 show cut-away views of the cylinder block assembly shownin FIG. 4.

FIGS. 15 and 16 show side views of the cylinder block shown in FIG. 3.

FIG. 17 shows a top view of the structural frame shown in FIG. 3.

FIG. 18 shows a top view of the cylinder block assembly shown in FIG. 4.

FIG. 19 show a bottom view of the cylinder block shown in FIG. 3.

FIGS. 3-19 are drawn approximately to scale.

DETAILED DESCRIPTION

Referring to FIG. 1, internal combustion engine 10, comprising aplurality of cylinders, one cylinder of which is shown in FIG. 1, iscontrolled by electronic engine controller 12. Engine 10 includescylinder 30 and cylinder walls 32 with piston 36 positioned therein andconnected to crankshaft 40. Cylinder 30 may also be referred to as acombustion chamber. Cylinder 30 is shown communicating with intakemanifold 44 and exhaust manifold 48 via respective intake valve 52 andexhaust valve 54. Each intake and exhaust valve may be operated by anintake cam 51 and an exhaust cam 53. Alternatively, one or more of theintake and exhaust valves may be operated by an electromechanicallycontrolled valve coil and armature assembly. The position of intake cam51 may be determined by intake cam sensor 55. The position of exhaustcam 53 may be determined by exhaust cam sensor 57.

Intake manifold 44 is also shown intermediate of intake valve 52 and airintake zip tube 42. Fuel is delivered to fuel injector 66 by a fuelsystem (not shown) including a fuel tank, fuel pump, and fuel rail (notshown). The engine 10 of FIG. 1 is configured such that the fuel isinjected directly into the engine cylinder, which is known to thoseskilled in the art as direct injection. Fuel injector 66 is suppliedoperating current from driver 68 which responds to controller 12. Inaddition, intake manifold 44 is shown communicating with optionalelectronic throttle 62 with throttle plate 64. In one example, a lowpressure direct injection system may be used, where fuel pressure can beraised to approximately 20-30 bar. Alternatively, a high pressure, dualstage, fuel system may be used to generate higher fuel pressures.Additionally or alternatively a fuel injector may be positioned upstreamof intake valve 52 and configured to inject fuel into the intakemanifold, which is known to those skilled in the art as port injection.

Distributorless ignition system 88 provides an ignition spark tocylinder 30 via spark plug 92 in response to controller 12. UniversalExhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaustmanifold 48 upstream of catalytic converter 70. Alternatively, atwo-state exhaust gas oxygen sensor may be substituted for UEGO sensor126.

Converter 70 can include multiple catalyst bricks, in one example. Inanother example, multiple emission control devices, each with multiplebricks, can be used. Converter 70 can be a three-way type catalyst inone example.

Controller 12 is shown in FIG. 1 as a conventional microcomputerincluding: microprocessor unit 102, input/output ports 104, read-onlymemory 106, random access memory 108, keep alive memory 110, and aconventional data bus. Controller 12 is shown receiving various signalsfrom sensors coupled to engine 10, in addition to those signalspreviously discussed, including: engine coolant temperature (ECT) fromtemperature sensor 112 coupled to cooling sleeve 114; a position sensor134 coupled to an accelerator pedal 130 for sensing force applied byfoot 132; a measurement of engine manifold pressure (MAP) from pressuresensor 122 coupled to intake manifold 44; an engine position sensor froma Hall effect sensor 118 sensing crankshaft 40 position; a measurementof air mass entering the engine from sensor 120; and a measurement ofthrottle position from sensor 58. Barometric pressure may also be sensed(sensor not shown) for processing by controller 12. In a preferredaspect of the present description, Hall effect sensor 118 produces apredetermined number of equally spaced pulses every revolution of thecrankshaft from which engine speed (RPM) can be determined.

During operation, each cylinder within engine 10 typically undergoes afour stroke cycle: the cycle includes the intake stroke, compressionstroke, expansion stroke, and exhaust stroke. During the intake stroke,generally, the exhaust valve 54 closes and intake valve 52 opens. Air isintroduced into cylinder 30 via intake manifold 44, and piston 36 movesto the bottom of the cylinder so as to increase the volume withincylinder 30. The position at which piston 36 is near the bottom of thecylinder and at the end of its stroke (e.g., when cylinder 30 is at itslargest volume) is typically referred to by those of skill in the art asbottom dead center (BDC). During the compression stroke, intake valve 52and exhaust valve 54 are closed. Piston 36 moves toward the cylinderhead so as to compress the air within cylinder 30. The point at whichpiston 36 is at the end of its stroke and closest to the cylinder head(e.g., when cylinder 30 is at its smallest volume) is typically referredto by those of skill in the art as top dead center (TDC). In a processhereinafter referred to as injection, fuel is introduced into thecylinder. In a process hereinafter referred to as ignition, the injectedfuel is ignited by known ignition means such as spark plug 92, resultingin combustion. During the expansion stroke, the expanding gases pushpiston 36 back to BDC. Crankshaft 40 converts piston movement into arotational torque of the rotary shaft. Finally, during the exhauststroke, the exhaust valve 54 opens to release the combusted air-fuelmixture to exhaust manifold 48 and the piston returns to TDC. Note thatthe above is shown merely as an example, and that intake and exhaustvalve opening and/or closing timings may vary, such as to providepositive or negative valve overlap, late intake valve closing, orvarious other examples.

Engine 10 may further include a turbocharger having a compressor 80positioned in intake manifold 44 coupled to a turbine 82 positioned inexhaust manifold 48. A driveshaft 84 may couple the compressor to theturbine. Thus, the turbocharger may include compressor 80, turbine 82,and driveshaft 84. Exhaust gases may be directed through the turbine,driving a rotor assembly which in turn rotates the driveshaft. In turnthe driveshaft rotates an impeller included in the compressor configuredto increase the density of the air delivered to cylinder 30. In thisway, the power output of the engine may be increased. In other examples,the compressor may be mechanically driven and turbine 82 may not beincluded in the engine. Further, in other examples, engine 10 may benaturally aspirated.

Referring to FIG. 2, it shows an example schematic depiction of engine10. Engine 10 includes a cylinder head 200 coupled to a cylinder blockassembly 202. It will be appreciated that the engine may further includevarious components for attaching the cylinder head to the cylinder blockassembly such as a head gasket (not shown), bolts or other suitableattachment apparatuses, etc.

The cylinder head and cylinder block assembly may each comprise at leastone cylinder. As discussed above with regard to FIG. 1, engine 10 mayinclude additional components configured to perform combustion in the atleast one cylinder.

The cylinder block assembly may include a cylinder block 204 coupled toa structural frame 206. The structural frame may include a lubricationcircuit 207 integrated therein. The lubrication circuit may include oilpassages 208, oil filter 210, oil pump 212, and solenoid valve 213. Theoil passages may be configured to provide lubrication to various enginecomponents such as the crankshaft and crankshaft bearings. The oilfilter may be coupled to an oil passage and configured to removeunwanted particulates from the oil passage. Moreover, the oil pump mayalso be coupled to an oil passage included in oil passages 208 andconfigured to increase the pressure in the lubrication circuit 207. Itwill be appreciated that additional integrated components may beincluded in structural frame 206. For example, the integrated componentsmay include balance shafts, block heaters, actuators, and sensors.

In one example, an oil pan 214 may be coupled to structural frame 206.The oil pan may be included in a lubrication circuit. Oil pump 212 mayalso be coupled to structural frame 206 via bolts or other suitablefasteners. Oil pump 212 may be configured to circulate oil from oil pan214 into oil passages 208. Thus, the oil pump may include a pick-updisposed in the oil pan as discussed in greater detail herein withregard to FIG. 3. It will be appreciated that oil passages 208 may befluidly coupled to oil passages included in cylinder head 200.

Engine 10 may further include a cooler 260 integrated into cylinderblock assembly 202. Cooler 260 may be configured to remove heat fromlubrication circuit 207. Cooler 260 may be an oil cooler.

Referring to FIG. 3, it shows an exploded perspective view of an examplecylinder block assembly 202. As depicted, cylinder block assembly 202includes cylinder block 204 positioned vertically above the structuralframe 206. Pump 212 and oil pan 214 are positioned vertically below thestructural frame 206. Directional vectors (i.e., the longitudinal,vertical, and lateral vectors) are provided for conceptualunderstanding. However, it will be appreciated that the cylinder blockassembly may be positioned in a number of orientations when included ina vehicle.

The cylinder block 204 further includes a plurality of crankshaftsupports 300 positioned at the bottom of the cylinder block 204 andconfigured to structurally support a crankshaft (not shown). In someexamples, the cylinder block may include two crankshaft supports. Thecrankshaft supports 300 may each include a bearing cap 304. The bearingcaps are configured to receive a crankshaft bearing. Thus, thecrankshaft supports form openings that are configured to receivecrankshaft bearing (not shown) configured to enable rotation of acrankshaft (not shown). It will be appreciated that the crankshaft mayinclude various components such as counterweights, journals, crankpinjournals, etc. The crankpin journals may each be coupled to a piston viaa connecting rod. In this way, combustion in the cylinders may be usedto rotate the crankshaft.

The bearing caps 304 may each include two structural frame attachmentrecesses 306, shown in greater detail in FIG. 19. The structural frameattachment recesses may be configured to receive a fastener such as abolt or other suitable attachment apparatus for coupling the structuralframe 206 to the cylinder block 204, discussed in greater detail hereinwith regard to FIG. 4. In this way, the structural frame 206 is coupledto the cylinder block 204 via the bearing caps 304. As shown, eachstructural frame attachment recess 306 extends vertically into thecrankshaft supports 300 from a bottom surface 308 of each the bearingcaps. Moreover, each structural frame attachment recess is positioned onthe lateral periphery of the bottom surface 308. However in otherexamples, the structural frame attachment recesses may be positioned inanother suitable location. Still further, in some examples thestructural frame attachment recesses may have an alternate geometricconfiguration and/or orientation.

As shown, crankshaft supports 300 are formed out of one continuous pieceof material. In other words, the crankshaft supports 300 aremanufactured via a single casting. Further in the depicted example, thecylinder block 204 is a one piece engine cylinder block constructed in asingle casting. The crankshaft supports may be cracked or otherwisedivided from the cylinder block 204 after casting so that a crankshaft(not shown) may be installed. After the crankshaft is properlypositioned, the pieces of the crankshaft supports may be subsequentlyfastened to the cylinder block after being divided from the cylinderblock. In this way, the structural integrity as well as the precision ofthe mated interface of the crankshaft supports may be increased whencompared to other cylinder block designs which may couple separatelyconstructed (e.g., cast) upper and lower pieces of the cylinder block toform the bearing cap. Moreover, NVH may also be reduced in the cylinderblock assembly when the crankshaft supports are constructed out of asingle piece of material.

Cylinder block 204 further includes an exterior front wall 310. Theexterior front wall 310 is shown in greater detail in FIG. 11. Likewise,cylinder block 204 further includes an exterior rear wall 312, show inFIG. 6. The exterior front wall 310 includes a first outermostcrankshaft support 1100. However, in the example in which the cylinderblock comprises two crankshaft supports, the exterior front wallincludes a first crankshaft support. The exterior rear wall 312 includesa second outermost crankshaft support 600, discussed in greater detailherein with regard to FIG. 6.

Continuing with FIG. 3, as depicted the cylinder block 204 includes aplurality of cylinders 314. However, in other examples the cylinderblock 204 may include a single cylinder. It will be appreciated thatcylinder 30 shown in FIG. 1 may be included in the plurality ofcylinders 314. The plurality of cylinders 314 may be conceptuallydivided into a first and a second cylinder bank (316 and 318). Cylinderbank 318 is shown in greater detail herein with regard to FIG. 18. Asshown, the engine may be in a V configuration in which opposingcylinders in each of the respective cylinder banks are positioned at anon-straight angle with respect to one another. In this way, thecylinders are arranged in a V. However, other cylinder configurationsare possible in other examples. A valley 320 may be positioned betweenthe first and second cylinder banks (316 and 318) in the cylinder block204. Cooler 260 may be positioned in the valley when the cylinder blockassembly 202 is assembled. A gasket 319 may be positioned between theoil cooler 260 and the cylinder block 204.

Cylinder block 204 further includes a first cylinder head engagingsurface 322 positioned at a top 323 of the cylinder block. Additionallyin the depicted example, the cylinder block includes a second cylinderhead engaging surface 324. However in other examples, the cylinder blockmay include a single cylinder head engaging surface. The first andsecond cylinder head engaging surface (322 and 324) may be configured tocouple to cylinder head 200 shown in FIG. 2. Suitable attachmentapparatuses, such as bolts, may be used to couple the cylinder head 200to the cylinder block 204 in some examples. When assembled the cylinderhead 200, shown in FIG. 2, and the cylinder block 204 are attached,combustion chambers may be formed in which combustion may be implementedas previously discussed with regard to FIG. 1. Suitable attachmentapparatuses (not shown) may be used to couple the cylinder head 200,shown in FIG. 2, to the cylinder block 204. Additionally, a seal (e.g.,gasket) may be positioned between cylinder head 200 and the first andsecond cylinder head engaging surfaces (322 and 324) to seal thecylinders.

Cylinder block 204 further includes two structural frame engagingsurfaces (326 and 328) configured to attach to two correspondingcylinder block sidewall engaging surfaces (330 and 332) included in thestructural frame 206 discussed in greater detail herein. The twostructural frame engaging surfaces (326 and 328) are positioned onopposing sides of the cylinder block 204. In the perspective view of thecylinder block assembly 202 shown in FIG. 3, the second structural frameengaging surface 328 cannot be fully viewed. However, the secondstructural frame engaging surface 328 as well as other componentsincluded in the other side of the cylinder block are shown in greaterdetail in FIG. 19. As depicted, the structural frame engaging surfaces(326 and 328) include a plurality of fastener openings 334. The fasteneropenings 334 may be configured to receive fasteners such as bolts whencoupled to the structural frame 206 discussed in greater detail hereinwith regard to FIG. 4.

Cylinder block 204 further includes a first exterior sidewall 333 and asecond exterior sidewall 335. The first cylinder block exterior sidewall333 is shown in greater detail in FIG. 15. Likewise, the second cylinderblock exterior sidewall 335 is shown in greater detail in FIG. 16. Thefirst cylinder block exterior sidewall 333 extends from the firstcylinder head engaging surface 322 to the first structural frameengaging surface 326 positioned between a centerline 339 of theplurality of crankshaft supports 300. Likewise, the second cylinderblock exterior sidewall 335 extends from the second cylinder headengaging surface 324 to the second structural frame engaging surface 328positioned between the centerline 339 of the plurality of crankshaftsupports 300. As shown, the structural frame engaging surfaces (326 and328) are substantially planar. However, in other examples, thestructural frame engaging surface may have another geometricconfiguration. For example, the height of the structural frame engagingsurfaces may vary.

Furthermore, the structural frame 206 includes a bottom surface 309 andtwo exterior sidewalls (i.e., a first structural frame exterior sidewall336 and a second structural frame exterior sidewall 338). In someexamples, the oil pan engaging surface 506, shown in FIG. 5 may be thebottom surface 309 of the structural frame 206. However, in otherexamples, the bottom surface 309 may include additional components. Thefirst structural frame exterior sidewall 336 extends from the bottomsurface 309 and includes the first cylinder block sidewall engagingsurface 330. Likewise, the second structural frame exterior sidewall 338extends from the bottom surface 309 and includes the second cylinderblock sidewall engaging surface 332. Furthermore, the first and secondstructural frame exterior sidewalls (336 and 338) extend above a top ofthe crankshaft supports 300 when the cylinder block assembly 202 isassembled. Additionally, the bottom surface 309 is below the crankshaftsupports 300. However, in other examples other configurations arepossible. For example, the first and second structural frame exteriorsidewalls (336 and 338) may not extend above a top of the crankshaftsupports. As depicted, the structural frame has a U shape. However, inother examples, other shapes are possible. The cylinder block sidewallengaging surfaces (330 and 332) are configured to attach to thestructural frame engaging surfaces (326 and 328) on the cylinder block204 and are positioned on opposite sides of the structural frame 206. Inthe depicted example, the cylinder block sidewall engaging surfaces (330and 332) form top surfaces of the structural frame. However, in otherexamples, other configurations are possible. The cylinder block sidewallengaging surfaces (330 and 332) include a plurality of fastener openings340 along their lengths. As shown, the cylinder block sidewall engagingsurfaces (330 and 332) are substantially planar and congruent a lateraland longitudinal plane. However, in other examples, alternate geometricconfigurations and orientations are possible. For example, the verticalheight of the sidewall engaging surfaces may vary.

The structural frame may further include a front cover engaging surfaces(382 and 384) extending along at least a portion of the structural frameexterior sidewalls (336 and 338). A first seal 370 may be positionedbetween the first cylinder block sidewall engaging surface 330 and thefirst structural frame engaging surface 326. Likewise, a second seal 372may be positioned between the second cylinder block sidewall engagingsurface 332 and the second structural frame engaging surface 328. Thefirst and second seals (370 and 372) may be substantially air and liquidtight. Exemplary seals include but are not limited to a gasket, anadhesive, etc.

The structural frame 206 includes an interior portion 342 adjacent tothe crankshaft supports 300 when the cylinder block assembly 202 isassembled. The interior portion 342 includes fastener openings 344configured to receive suitable fasteners such as bolts. As discussed ingreater detail herein, the fasteners may extend through the fasteneropenings 344 in the structural frame 206 as well as the attachmentrecesses 306 in the cylinder block 204. The interior portion 342 isdescribed in greater detail herein with regard to FIG. 17.

In some examples, cylinder block 204 and structural frame 206 may beconstructed out of different materials. Specifically in one example,cylinder block 204 may be constructed out of a material having a greaterstrength to volume ratio than structural frame 206. However, in otherexamples, the cylinder block and structural frame may be constructed outof substantially identical materials. Exemplary materials that may beused to construct the cylinder block include a gray iron, compactedgraphite iron, ductile iron, aluminum, magnesium, and/or plastic.Exemplary materials used to construct the structural frame include grayiron, compacted graphite iron, ductile iron, aluminum, magnesium, and/orplastic. In one particular example, the cylinder block may beconstructed out of a compacted graphite iron and the structural framemay be constructed out of aluminum. In this way, increased structuralintegrity may be provided to locations in the cylinder block assemblythat experience greater stress, such as the combustion chambers andsurrounding areas. Moreover, the volumetric size of the cylinder blockassembly may be reduced when the aforementioned combination of materialsis utilized in the cylinder block assembly as opposed to a cylinderblock constructed only out of aluminum. Still further, the structuralframe may be constructed out of a material having a greater strength toweight ratio than the material used to construct the cylinder block,thereby enabling weight reduction of the cylinder block assembly 202.

The cylinder block assembly further includes oil pan 214 positionedvertically below the structural frame 206 and cylinder block 204. Whenassembled oil pump 212 may be coupled to an oil pan engaging surface506, shown in FIG. 5, located on a bottom side of the structural frame.Moreover, the oil pump includes oil pick-up 350 positioned in the oilpan when the cylinder block assembly is assembled and an outlet port 352configured to deliver oil to an oil passage 510, shown in FIG. 5, in thestructural frame 206. In this way, the oil pump 212 may receive oil fromthe oil pan 214. The cylinder block assembly 202 further includes oilfilter 210 and an oil filter port 550 for receiving the oil filter 210.The oil filter may be coupled to a plate body cooler 360. Plate bodycooler 360 cools engine oil as it is circulated throughout the engine.

The cylinder block assembly 202 further includes oil pan 214. The oilpan includes a third structural frame engaging surface 374 havingfastener openings 376 for receiving fasteners. A seal 378 may bepositioned between the third structural frame engaging surface 374 andan oil pan engaging surface 506 included in the structural frame shownin FIG. 5, discussed in greater detail herein.

The structural frame 206 further includes a sensor mounting boss 380 forreceiving a sensor, such as an oil pressure sensor. As shown the sensormounting boss 380 is positioned on the first structural frame exteriorsidewall 336. However, the sensor mounting boss may be positioned inanother suitable location such as on the second structural frameexterior sidewall 338 in other examples.

FIG. 4 shows another perspective view of the cylinder block assembly 202in an assembled configuration. As shown, the cylinder block 204 isattached to the structural frame 206. As shown, the first and secondcylinder block sidewall engaging surface (330 and 332) on the structuralframe 206 may be coupled to corresponding structural frame engagingsurfaces (326 and 328). It will be appreciated that the structural frameengaging surfaces and cylinder block sidewall engaging surfaces may becorresponding contoured to attach to on another such that the surfacesare in face sharing contact. However, in some examples seals may bepositioned between the engaging surfaces as previously discussed.

Fasteners 400 extend through fastener openings (334 and 340) in both ofthe structural frame engaging surfaces (326 and 328) and the cylinderblock sidewall engaging surfaces (330 and 332). In this way, theengaging surfaces may be secured to one another. Although FIG. 4 shows asingle side of the cylinder block assembly 202 in which the engagingsurfaces are attached it will be appreciated that engaging surfaces onthe opposing side of the cylinder block assembly may also be coupled.

FIG. 5 shows the exterior portion 500 of the bottom surface 309 of thestructural frame 206. As shown, the fastener openings 340 extend fromthe interior portion 342 of the structural frame 206, shown in FIG. 3,to the exterior portion 500 of the structural frame 206, thereby formingopenings. As previously discussed fasteners such as bolts may extendthrough the fastener openings 340 when the cylinder block assembly is inan assembled configuration. In the depicted example, the structuralframe 206 has a ladder configuration. In the ladder configuration thestructural frame 206 includes supports 502 that are laterally aligned.When the structural frame 206 has a ladder configuration it may bereferred to as a ladder frame. Specifically in the ladder configuration,the supports 502 are aligned with the crankshaft supports 300, shown inFIG. 3, when the cylinder block assembly 202 is assembly, therebyproviding structural support to the cylinder block 204 and crankshaft.It will be appreciated that when the cylinder block 204 is attached tothe structural frame 206 in this way, the structural integrity of thecylinder block assembly may be increased and the NVH during engineoperation may be reduced. However, other support alignments are possiblein other examples or the supports may not be included in the structuralframe. An oil pan engaging surface 506 is also shown in FIG. 5. The oilpan engaging surface includes fastener opening 504 configured to receivefasteners when attached to the oil pan 214. The structural frame 206further includes an oil passage 510 configured to receive oil from theoutlet port 352 of the oil pump 212. Structural frame 206 also includesoil filter port 550 for supplying and receiving oil from oil filter 210.

FIG. 6 shows the exterior rear wall 312 of the cylinder block 204including an outermost crankshaft support 600 and corresponding bearingcap 602. The cylinder head engaging surfaces (322 and 324) and the firstand second structural frame engaging surfaces (326 and 328) are alsoshown in FIG. 6. Similarly, FIG. 7 shows a rear end 700 of thestructural frame 206. The first and second cylinder block sidewallengaging surfaces (330 and 332) are also depicted in FIG. 7.

FIG. 8 shows a view of the rear portion 800 of the cylinder blockassembly 202 including the rear wall 312 of the cylinder block 204 andthe rear end 700 of the structural frame 206 in an assembledconfiguration. As shown, the structural frame 206 may be coupled to theexterior rear wall 312 of the cylinder block 204. As shown, the rear end700 of the structural frame 206 and the rear wall 312 provide atransmission bell housing engaging surface 802. The transmission bellhousing engaging surface 802 may be coupled to a transmission bellhousing (not shown). In this way, the transmission may be attached tothe cylinder block assembly 202. Furthermore, the structural frame 206isolates at least a portion of an interior of the engine 10 from thetransmission (not shown). As shown, the transmission bell housingengaging surface is positioned near the periphery of the rear end of thecylinder block assembly 202. However, in other examples the transmissionbell housing engaging surface may be positioned in another suitablelocation. A plurality of connection recesses 804 are included in thetransmission bell housing engaging surface 802. The connection recessesmay be configured to receive fasteners for connecting the transmissionbell housing to the cylinder block assembly 202. Further, the connectionrecesses 804 are shown extending a full 360° around the centerline 339of the crankshaft supports. It will be appreciated that in FIG. 8 thecenterline 339 extends into and out of the page. As such, the rearportion of the cylinder block assembly 202 is arranged in a circularshape. The cylinder block 204 forms a top portion of the circle, andstructural frame 206 forms a bottom portion of the circle. Thus,cylinder block 204 and structural frame 206 provide at least a portionof the support keeping the transmission bell housing in place when thetransmission bell housing is coupled to cylinder block assembly 202. Inthis way, the connection between the transmission and the cylinder blockassembly may be strengthened thereby reducing NVH within the vehicle.

Furthermore, the structural frame 206 may include a rear cover engagingsurface 806 for a rear main crankshaft seal housing. Likewise, thecylinder block 204 may include a rear cover engaging surface 808 for therear main crankshaft seal housing. In this way, the crankshaft may besubstantially sealed. Both the engaging surfaced 806 and 808 may includefastener openings 810 for receiving fasteners.

FIG. 8 also shows the cylinder head engaging surfaces (322 and 324), thefirst structural frame engaging surface 326 attached to the firstcylinder block sidewall engaging surface 330, and the second structuralframe engaging surface 328 attached to the second cylinder blocksidewall engaging surface 332.

FIGS. 9 and 10 show side views of the laterally opposing sidewalls ofthe cylinder block assembly 202. Specifically FIG. 9 shows a firstassembly sidewall 900 of the cylinder block assembly 202 and FIG. 10shows a second assembly sidewall 1000 of the cylinder block assembly202. As shown, a portion of the cylinder block 204 and the structuralframe 206 included in the cylinder block assembly 202 form the assemblysidewalls (900 and 1000). Specifically, the first assembly sidewall 900includes the first cylinder block exterior sidewall 333 and the firststructural frame exterior sidewall 336. Furthermore, the firststructural frame exterior sidewall 336 included in the sidewall 900includes stiffening webbing 902. Moreover, in the depicted example, thefirst structural frame exterior sidewall 336 provides more than half avertical length of the first assembly sidewall 900. However in otherexamples, other configurations are possible. Likewise, as shown in FIG.10, the second assembly sidewall 1000 includes the cylinder block secondexterior sidewall 335 and the structural frame second exterior sidewall338. Additionally, the structural frame second exterior sidewall 338included in the second assembly sidewall 1000 includes stiffeningwebbing 1002. The stiffening webbing strengthens the walls withouthaving to increase the wall strength throughout cylinder block assembly202 and specifically the structural frame 206. As such, stiffeningwebbing (902 and 1002) strengthens the structural frame 206 of thecylinder block assembly 202 without adding significant weight to thestructural frame 206. Further in the depicted example, the structuralframe second exterior sidewall 338 provides more than half a verticallength of the second assembly sidewall 1000. However in other examples,other configurations are possible.

FIG. 9 also shows the first structural frame engaging surface 326coupled to the first cylinder block sidewall engaging surface 330. Asshown, fasteners 400 may extend through the first structural frameengaging surface and the first cylinder block sidewall engaging surfaceto attach the cylinder block 204 to the structural frame 206. Cylinderhead engaging surface 322 is also depicted in FIG. 9.

FIG. 10 also shows the second structural frame engaging surface 328coupled to the second cylinder block sidewall engaging surface 332. Asshown, fasteners 400 may extend through the second structural frameengaging surface and the second cylinder block sidewall engaging surfaceto attach the cylinder block 204 to the structural frame 206.

FIG. 11 shows a view of the exterior front wall 310 of the cylinderblock 204. As previously discussed, the exterior front wall 310 includesan outermost crankshaft support 1100 and corresponding bearing cap 1102.The cylinder head engaging surfaces (322 and 324) and the first andsecond structural frame engaging surface (326 and 328) are also shown inFIG. 11. FIG. 12 shows a detailed front side 1200 of the structuralframe 206. The front side 1200 of the structural frame 206 may include afront partition 1202. As shown, the front partition 1202 couples thefirst and second structural frame exterior side walls (336 and 338). Thecylinder head engaging surfaces (322 and 324) and the first and secondcylinder block sidewall engaging surfaces (330 and 332) are also shownin FIG. 12.

Referring to FIG. 13, it shows a cut-away view of the cylinder blockassembly 202. Cutting plane 450, shown in FIG. 4, defines thecross-section shown in FIG. 13. One crankshaft support 1300 included inthe plurality of crankshaft supports 300 is shown. The centerline 339extends into and out of the page. As shown, a fastener 1302 included inthe plurality of fasteners 400, shown in FIG. 4, extends through thefastener opening 1304 included in the plurality of fastener openings334, shown in FIG. 3, in the first structural frame engaging surface 326and fastener opening 1305 included in the plurality of fastener openings340, shown in FIG. 3, in the first cylinder block sidewall engagingsurface 330. The fastener 1302 as well as the other fasteners 400, shownin FIG. 4, couple the structural frame 206 to the cylinder block 204vertically above the centerline 239 of the crankshaft relative to thebottom of the cylinder block 204 and the structural frame 206. In thisway, the first and second structural frame exterior sidewalls (336 and338) of the structural frame 206 extend above the centerline 339 of thecrankshaft supports 300. Therefore, the first and second cylinder blockexterior sidewalls (333 and 335) end above the centerline 339 of thecrankshaft supports 300. Likewise, the first and second structural frameexterior sidewalls (336 and 338) end above the centerline 339 of thecrankshaft supports 300.

When the cylinder block is coupled to the structural frame above thecenterline of the crankshaft supports, the cylinder block assembly maybe provided with increased structural integrity when compared to othercylinder block designs that connect the cylinder block to the framevertically at or below the centerline of the crankshaft supports.Moreover, NVH may be decreased within the engine when this type ofconfiguration is utilized due to the increased structural integrity ofthe cylinder block assembly. Further, extending the first and secondstructural frame exterior sidewalls (336 and 338) above the centerline339 of the crankshaft supports allows the structural frame 206 to beconstructed of a lower strength to volume material so that engine weightmay be reduced.

Additionally, fasteners 1306 may extend through a fastener openingincluded in the plurality of fastener openings 344, shown in FIG. 3. Inthis way, the structural frame 206 may be coupled to the cylinder blockin another location, further increasing the reinforcement provided bythe structural frame 206. FIG. 13 also shows the centerlines 1350 of thecylinders are positioned at a non-straight angle 1352 with respect toone another. However, in other examples other cylinder arrangements arepossible. Fasteners 1307 may be used to attach a lower portion of thecrankshaft support 1300 to an upper portion of the crankshaft support1300 after it is cracked or otherwise divided. However, in otherembodiments the cylinder block assembly 202 may not include connectionapparatuses 1307. Example fasteners include bolts, screws, or othersuitable attachment apparatuses.

The second cylinder block sidewall engaging surface 332 and the secondstructural frame engaging surface 328 are also shown in FIG. 13. It willbe appreciated that the second cylinder block sidewall engaging surfaceand the second structural frame engaging surface may include similarfasteners and fastener opening to fastener 1302 and fastener opening1304 and 1305 shown in FIG. 13.

Referring to FIG. 14, it shows another cut-away view of cylinder blockassembly 202. Cutting plane 452, shown in FIG. 4, defines thecross-section shown in FIG. 14. The cut-away show that the first andsecond structural frame exterior sidewalls (336 and 338) of thestructural frame 206 as well as the first and second cylinder blockexterior sidewalls (333 and 335) of the cylinder block 204 may vary inthickness. FIG. 14 also shows the cylinder head engaging surfaces (322and 324).

FIG. 15 shows a side view of the structural frame 206. As shown, thecrankshaft supports 300 extend in a vertical direction. However, inother examples the crankshaft supports may have an alternate orientationand/or geometry. The cylinder head engaging surface 322, the firstcylinder block exterior sidewall 333, the structural frame engagingsurface 326, and the centerline 339 of the plurality of crankshaftsupports 300 are also shown in FIG. 15. As previously discussed, thestructural frame engaging surface 326 is positioned vertically above thecenterline 339. FIG. 16 shows another side view of the structural frame206. FIG. 16 additionally shows the cylinder head engaging surface 324,the second cylinder block exterior sidewall 335, the second structuralframe engaging surface 328, and the centerline 339.

FIG. 17 shows a top view if the interior of the structural frame 206. Asshown, supports 1700 may laterally extend across the structural frame206. The supports are laterally and longitudinally aligned with thebearing caps to provide increased support to the cylinder block, therebyincreasing the cylinder block assembly's strength and reducing NVHduring engine operation. As shown, the fastener openings 344 are locatednear the lateral periphery of the supports 1700. Additionally, thecylinder block sidewall engaging surfaces (330 and 332) and the fasteneropenings 340 included in the cylinder block sidewall engaging surfaces(330 and 332) are shown. The first seal 370 and the second seal 372 arealso shown in FIG. 17.

FIG. 18 shows a top view of the cylinder block 204. Cylinders 314 arearranged in two groups of three cylinders. However, in alternativeexamples, cylinder block 204 may be comprised of a single cylinder, twogroups of four cylinders, two groups of two cylinders, or two groups ofone cylinder. The groups of cylinder may be referred to as cylinderbanks. As shown, the two groups of three cylinders are offset from eachother in a longitudinal direction. In this example, cylinder block 204is configured for over head camshafts. However, in alternative examples,cylinder block 204 may be configured for a push-rod configuration.Additionally, the valley 320 between the cylinder banks is shown. An oilpassage 1800 may be fluidly coupled to the cooler 260, shown in FIGS. 3and 4, positioned in the valley 320. In this way, oil passage 1800 maybe positioned to receive oil from cooler 260. Specifically, oil passage1800 may receive oil from cooler 260. Oil passage 1800 may be fluidlycoupled to an oil gallery included in the structural frame 206 and/or anoil gallery included in the cylinder block 204. The cylinder headengaging surfaces (322 and 324) are also shown in FIG. 18.

FIG. 19 shows a view of the bottom 1900 of the cylinder block 204. Thestructural frame attachment recesses 306 are positioned proximate to thelateral periphery of the bottom surfaces 308 of the bearing caps 304.However, the attachment recesses 306 may be positioned in anothersuitable location in other examples. As previously discussed, thecylinder block 204 includes a first and second structural frame engagingsurface (326 and 328) having fastener opening 334 configured to receivefasteners for coupling the cylinder block 204 to the structural frame206, shown in FIG. 3.

The cylinder block assembly 202 and engine 10 shown in FIGS. 2-19provide for a structural frame including a bottom surface, first andsecond cylinder block sidewall engaging surfaces, the first and secondcylinder block sidewall engaging surfaces positioned above the bottomsurface at a height that is above a centerline of a crankshaft supportincluded in a cylinder block when the structural frame is coupled to thecylinder block.

The structural frame may further include where an oil pan engagingsurface is the bottom surface of the structural frame, and where thefirst and second cylinder block sidewall engaging surfaces form topsurfaces of the structural frame. The structural frame may furtherinclude a plurality of fastener openings along the length of the firstand second cylinder block sidewall engaging surfaces.

The structural frame may further include where the structural frame isconstructed of a material having a strength to volume ratio less than astrength to volume ratio of an engine block, when the structural frameis coupled to the engine block. The structural frame may further includewhere the first and second cylinder block sidewall engaging surfaces arepositioned on opposite sides of the structural frame. The structuralframe may further include where first and second cylinder block sidewallengaging surfaces are part of first and second structural framesidewalls, the first and second structural frame sidewalls includingstiffening webbing. The structural frame may further include atransmission bell housing engaging surface. The structural frame mayfurther include where the bottom surface is an oil pan engaging surface.

The cylinder block assembly 202 and engine 10 shown in FIGS. 2-19 alsoprovide for a structural frame including a oil pan engaging surface,first and second cylinder block sidewall engaging surfaces, the firstand second cylinder block sidewall engaging surfaces positioned abovethe oil pan engaging surface at a height that is above a centerline of acrankshaft when the structural frame is coupled to an engine block, anoil pump pick-up, and a oil filter, the cylinder block sidewall engagingsurfaces positioned at a top of the structural frame.

The structural frame may further include where the structural frame isconstructed of a material having a strength to volume ratio less than astrength to volume ratio of an engine block, when the structural frameis coupled to the engine block.

The structural frame may further include where the structural frame ispart of a sidewall of a cylinder block assembly when the structuralframe is coupled to an engine block. The structural frame may furtherinclude a transmission bell housing engaging surface. The structuralframe may further include where the structural frame isolates at least aportion of an interior of an engine from a transmission when thestructural frame is coupled to an engine block and a transmission. Thestructural frame may further include rear cover engaging surface.

The structural frame may further include wherein the first and secondcylinder block sidewall engaging surfaces are included in a first andsecond structural frame exterior sidewall and supports laterally extendfrom the first structural frame exterior sidewall to the secondstructural frame exterior sidewall.

The cylinder block assembly 202 and engine 10 shown in FIGS. 2-19 alsoprovide for a structural frame including a cylinder block having acrankshaft opening with a centerline, a structural frame coupled to thecylinder block, the frame including an oil pan engaging surface, firstand second cylinder block sidewall engaging surfaces, the first andsecond cylinder block sidewall engaging surfaces positioned above theoil pan engaging surface at a height that is above the centerlinestructural frame, at least one sensor mounting boss, and at least onefastener opening positioned to receive a fastener coupling thestructural frame to a bearing cap.

The structural frame may also include where two fastener openings arepositioned within the structural frame to receive two fasteners couplingthe structural frame to a bearing cap. The structural frame may alsoinclude an engine front cover engaging surface. The structural frame mayalso include an engine oil cooler mounting boss. The structural framemay also include supports extending laterally from a first structuralframe exterior sidewall to a second structural frame exterior sidewall.

It will be appreciated that the configurations and/or approachesdescribed herein are exemplary in nature, and that these specificexamples or examples are not to be considered in a limiting sense,because numerous variations are possible. The subject matter of thepresent disclosure includes all novel and nonobvious combinations andsubcombinations of the various features, functions, acts, and/orproperties disclosed herein, as well as any and all equivalents thereof.

This concludes the description. The reading of it by those skilled inthe art would bring to mind many alterations and modifications withoutdeparting from the spirit and the scope of the description. For example,single cylinder, I2, I3, I4, I5, V6, V8, V10, V12 and V16 enginesoperating in natural gas, gasoline, diesel, or alternative fuelconfigurations could use the present description to advantage.

1. An engine, comprising: a structural frame including a bottom surface; first and second cylinder block sidewall engaging surfaces; and a cylinder block including a cylinder, at least two crankshaft supports at a bottom of the cylinder block, a cylinder head engaging surface at a top of the cylinder block, and first and second exterior sidewalls, the first exterior sidewall extending from the cylinder head engaging surface to the first structural frame sidewall engaging surface positioned above a centerline of a crankshaft supported by the two crankshaft supports, the first and second cylinder block sidewall engaging surfaces positioned above the bottom surface and above the centerline.
 2. The engine of claim 1 further comprising an oil filter port.
 3. The engine of claim 2, further comprising an oil pump, the oil pump coupled to the structural frame, and wherein the oil filter port is positioned on either of the first or second structural frame exterior sidewalls.
 4. The cylinder block of claim 1, where the second exterior sidewall extends from a second cylinder head engaging surface to a second structural frame engaging surface positioned above the centerline of the crankshaft relative to the bottom of the cylinder block.
 5. The engine of claim 1, where an oil pan engaging surface is the bottom surface of the structural frame.
 6. The engine of claim 1, further comprising a plurality of fastener openings along the length of the first and second cylinder block sidewall engaging surfaces.
 7. The engine of claim 1, where the structural frame is constructed of a material having a strength to volume ratio less than a strength to volume ratio of an engine block, when the structural frame is coupled to the engine block.
 8. The engine of claim 1, where the first and second cylinder block sidewall engaging surfaces are positioned on opposite sides of the structural frame.
 9. The engine of claim 1, where first and second cylinder block sidewall engaging surfaces are part of first and second structural frame sidewalls, the first and second structural frame sidewalls including stiffening webbing.
 10. The engine of claim 1, wherein the structural frame further comprises a transmission bell housing engaging surface.
 11. The engine of claim 1, where the first exterior sidewall extends from the cylinder head engaging surface to the first structural frame engaging surface positioned above the centerline of the crankshaft relative to the bottom of the cylinder block.
 12. The engine of claim 1, where the cylinder block is a one piece engine cylinder block.
 13. The engine of claim 1, wherein the cylinder block further comprises an exterior front wall and an exterior rear wall, where the exterior front wall includes one of the two crankshaft supports, where the exterior rear wall includes one of the two crankshaft supports, and where the two crankshaft supports surround the crankshaft.
 14. The engine of claim 13, wherein the structural frame is coupled to the exterior rear wall, where the structural frame and the exterior rear wall provide engine rear cover engaging surfaces, and where the structural frame is coupled to a transmission bell housing.
 15. The engine of claim 1, where the cylinder block includes a plurality of cylinders arranged in a V, and further comprising a second cylinder head engaging surface at the top of the cylinder block.
 16. The engine of claim 1, where the cylinder block is formed as a one piece engine cylinder block, and where two bearing caps are subsequently divided from the cylinder block.
 17. The engine of claim 1, where the cylinder block is formed as a one piece engine cylinder block, and two bearing caps are subsequently divided from the cylinder block, the two bearing caps each including two structural frame attachment recesses.
 18. An engine, comprising: a cylinder block having two or more cylinders arranged in a non-straight angle, two crankshaft supports at a bottom of the cylinder block, first and second cylinder head engaging surfaces at a top of the cylinder block, first and second exterior sidewalls, the first exterior sidewall extending from the first cylinder head engaging surface to a first structural frame engaging surface positioned above a centerline of a crankshaft supported by the two crankshaft supports, the second exterior sidewall extending from the second cylinder head engaging surface to a second structural frame engaging surface positioned above the centerline of the crankshaft, a transmission bell housing engaging surface at a rear of the cylinder block, the first and second structural frame engaging surfaces each including a plurality of fastener openings; and a structural frame including first and second structural frame exterior sidewalls, the first structural frame exterior sidewall coupled to the first cylinder block exterior sidewall, the second structural frame exterior sidewall coupled to the second cylinder block exterior sidewall, the first structural frame exterior sidewall and the second structural frame exterior sidewall coupled via a transmission bell housing engaging surface at a rear of the structural frame.
 19. A cylinder block assembly comprising: a cylinder block having a crankshaft opening with a centerline; a structural frame coupled to the cylinder block; the frame including: an oil pan engaging surface, first and second cylinder block sidewall engaging surfaces, the first and second cylinder block sidewall engaging surfaces positioned above the oil pan engaging surface at a height that is above the centerline, and. an oil pan coupled to the frame.
 20. The assembly of claim 19 wherein the structural frame further comprises a transmission bell housing engaging surface. 